System of machine maintenance

ABSTRACT

A system for remote maintenance for a machine. The system includes a database having information for a plurality of machines. A customer accesses the database in order to receive an illustration of at least one of said plurality of machines. Thereafter, the customer identifies a portion of the machine illustration and is provided with ordering data for that portion of the machine (e.g., a machine component, sub-component or part). Using this ordering data the customer can order parts of its machine. Additionally, using an imaging device, such as a digital camera, the customer can transmit images of the machine to an off-site expert and receive real-time information related to the assembly, installation, repair or maintenance of the machine.

RELATED APPLICATION

[0001] This application claims priority of U.S. Provisional PatentApplication 60/238,214 filed Oct. 5, 2000 and is incorporated herein byreference.

BACKGROUND

[0002] 1. Field of the Invention

[0003] The present invention relates generally to a system for machinemaintenance. More particularly, the present invention concerns a systemfor receiving information (including assembly, installation or repairinstructions) from an expert at a remote location and for remotelyidentifying and ordering one or more components, subcomponent or partsfor a machine.

[0004] 2. Reference to Related Art

[0005] Modern manufacturing operations depend upon machines to performall manner of tasks. Indeed, machines have become so important totoday's economy that the failure of even a single machine (e.g., anautomotive assembly machine) can cost a manufacturer many thousands ofdollars for every minute that the machine is disabled. Therefore, animportant element of any manufacturing operation is the care andmaintenance of its machines. To this end, it is essential that amanufacturer have in place a maintenance system that is designed to keepits operations and its machines running at peak performance levels.

[0006] Regardless of the lengths to which a manufacturer might go tomaintain its machines in good working order, an inevitable aspect of atypical maintenance program involves machine repairs. Unfortunately, ifthe machine in need of repair is an assembly station or some othercomplex piece of equipment, it is often necessary to call in an outsideexpert or engineer to execute the required repair. If this outsideexpert is located beyond the manufacturer's local area, he or she mustbe flown in and possibly lodged overnight. Furthermore, if the machinein need of repair is a custom designed machine or has certain uniquefeatures, it may be necessary for the manufacturer to keep the expert“on call”; which can significantly increase the manufacturer's overallrepair budget.

[0007] No matter where the expert is located, until the repair isaccomplished, the manufacturer must try to continue its operationswithout the machine. However, depending upon the machine and the size ofthe manufacturer, continued operations may not be possible until therepairs are complete. Therefore, it should be immediately clear thatprior art systems that rely upon the arrival of on-site experts are notcost effective, are inefficient and can have a significant impact onrevenue and employment.

[0008] In addition to machine repairs, an effective maintenance systemmust also allow the user to order and purchase replacement parts. Thecurrent art provides an order process for machine parts whereby theowner of a machine identifies a part for replacement, contacts amanufacturer or distributor of the part, and places an order. There are,however, several disadvantages to the present art. One such disadvantageis the time, effort, and expense required to identify the part bydescription and part number. Typically, this involves a process wherebythe owner of the machine must power down the machine and remove one ormore components to isolate the component containing the part to bereplaced. Once the owner isolates the component, the owner must furtherdisassemble the component to locate the subcomponent or part to bereplaced. Once disassembled, the owner must identify reorderinginformation located on the part itself and on the machine; e.g., a partnumber and a model number for the machine.

[0009] A second disadvantage is the time, effort, and expense associatedwith locating a factory approved replacement source and placing anorder. Typically, this location process involves multiple phone calls tovarious sources in an attempt to locate the replacement part, or lengthyreorder forms that must be manually completed and submitted to one ormore sources. As can be seen, the aforementioned reordering steps resultin periods of downtime for the machine involved, thus incurringsignificant costs attributed to the lost productivity during thoseperiods of downtime; the manual labor involved in identifying the partto be ordered; and the manual process by which an order is placed.

[0010] Therefore, what is needed is a maintenance system that allowsrepairs to be accomplished quickly and a fast, efficient, end-to-endorder process whereby an owner of a machine (hereafter, customer) canreadily identify a part to be replaced and electronically order thatpart based on the identification information.

SUMMARY OF THE INVENTION

[0011] The present invention provides a system that overcomes all of theabove-mentioned disadvantages of the previously known systems. In brief,the system includes a component ordering system that includes the stepsof: providing a database having information for a plurality of machines;providing access to said database to display an illustration of at leastone of said plurality of machines; and sending ordering data for aselected portion of said illustration representing at least onecomponent of the at least one machine.

[0012] More specifically, in the component ordering system, the customerutilizes a user interface (e.g., a PC) to access a database that isprovided at a location remote from the customer. Preferably, thisdatabase stores information concerning one or more of the customer'smachine(s) (i.e., manufacturing data, dimension, description, manuals,illustrations of the machine and related documentation). Using theInternet or other means of electronic communication, the customeraccesses the database with the user interface, selects one of itsmachines and is shown an illustration of the selected machine on theuser interface. The customer then selects a portion of the illustrationrepresenting at least one component of the machine. The selection of acomponent of the machine results in the transmission of ordering datafor that component from the database and the display of that data on theuser interface. The customer then uses the ordering data to transmit anorder for the component to the manufacturer or a vendor. Finally, thecustomer receives a confirmation that the order has been processed.

[0013] It should be understood that the database and illustration of themachine are preferably arranged using a hierarchical model wherebyinformation is presented to the customer in varying degrees of detail,starting with high-level information pertaining to the machine andending with detailed information pertaining to a part of the machine. Itwill also be appreciated that the customer can select a portion of theselected component and obtain ordering data for a sub-component of themachine. Indeed, this process can be carried forward and repeated toprovide the customer with ordering data for smaller and smaller portionsof the machine.

[0014] The component ordering system may also alternatively include anaccounting system into which the ordering data can be transferred. Theaccounting system permits the customer to generate electronic or printeddocumentation for each order.

[0015] Additionally, the system of the present invention mayalternatively include an expert information system that allows thecustomer to receive expert information, including assembly, installationand repair instructions, from an expert or engineer for the machine thatis stationed at a remote location. This further embodiment of theinvention includes the step of providing an imaging device (such as adigital video camera) and connecting that imaging device to the userinterface. Using the imaging device, the customer transmits (via theInternet) real-time images of the machine to a user interface for anoff-site expert. The expert (who was preferably contacted ahead oftime), reviews the images of the machine and can convey expertinformation (including assembly, installation and repair instructions)to the customer using the user interface or through the use anothermeans of communication (e.g., telephone, video conference, etc.).Finally, the customer receives the instructions regarding the machinefrom the expert and executes the any necessary actions.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]FIG. 1 is a diagrammatic view of a system of machine maintenancein accordance with the present invention; and

[0017]FIG. 2 is a flowchart view of a preferred embodiment andalternative embodiments of the system of the present invention.

DETAILED DESCRIPTION

[0018] Referring now to FIGS. 1 and 2, the system of machine maintenance10 of the present invention preferably includes a component orderingsystem 12 and an expert information system 14. Preferably, the componentordering system 12 uses a hierarchical model whereby information ispresented to the customer in varying degrees of detail, starting withhigh-level information pertaining to the machine and ending withdetailed information pertaining to a customer's machine 100. The expertinformation system 14 uses an imaging device 102 to transmit images of amachine 100 to an off-site expert 104 so that a customer can receiveinstructions from the expert 104.

[0019] Still referring to FIGS. 1 and 2, preferably, the system 10 ofthe present invention includes a first step 20 of providing a database108 having information (i.e., manufacturing data, dimension,description, manuals, illustrations of the machine and relateddocumentation) for a plurality of machines. The database 108 ispreferably stored in a user interfaceable device, such as a web siteserver 110.

[0020] In a second step 22, the customer is provided with access to thedatabase and is able to display an illustration of at least one of thecustomer's machines contained in the database. In this second step 22,the customer utilizes a user interface 106 (such as a P.C.) to accessthe database 108 via a two-way communications link 112 such as theInternet, radio, cable or satellite link. Initially, the web server 110displays a login web page including text fields for a login andpassword. The customer utilizes the user interface 106 to enter thelogin and password previously assigned to the customer. Preferably, theuser interface 106 is capable of displaying a representation of thecustomer's machine 100 and transmitting data (e.g., a computer devicesuch a laptop PC connected to the Internet).

[0021] Upon gaining access to the database 108 the customer views one ormore web pages associated with the web site server 110. The web siteserver 110 and its associated software retrieve from the database 108and transmit to the customer a list of machines owned or leased by thecustomer corresponding to the login and password. Preferably, the website server 110 transmits and displays the list of machines and theircorresponding model numbers on a web page, and the customer selects themachine for which a component is to be ordered.

[0022] Upon selection of a machine from the database 108 (e.g., such asa packaging machine composed of a number of stock or customsubcomponents), the web site server 110 and its associated softwaretransmit for display on the user interface 106 a web page depicting anillustration of the machine 100, including its major components. Thisillustration of the machine 100 is particularly important when thecustomer possesses a variety of different machines; some or all of whichmay be customized or otherwise unique. Specifically, the illustration ofthe machine 100 assists the customer in ensuring that it has chosen thecorrect machine.

[0023] In a fourth step 26, the customer, utilizing an input device suchas a mouse, passes the cursor over an area of the illustrationcorresponding to a component to be ordered or reordered, and selects thecomponent by clicking on the mouse.

[0024] In a fifth step 28, the web site server 110 and its associatedsoftware retrieves from the database 108 ordering data pertinent to theselected component, and transmits and displays the same in the form ofan illustration including the subcomponents of the illustratedcomponent. Preferably, the ordering data for the selected componentincludes both technical information for the component (i.e.,descriptions, dimensions, functions, tolerances and machinedocumentation) and sales information (i.e., part numbers, descriptions,per unit or discount unit costs).

[0025] The customer may also view the illustrated component, and repeatthe previous selection process, by the additional step 29 of selecting asub-component of the component to be ordered. In selecting asub-component, the customer uses the input device to pass the cursorover an area of the now illustrated, and preferably enlarged, component(which, as discussed above was previously selected) corresponding to asub-component to be ordered or reordered, and selects the sub-componentcomponent by clicking the input device. It should be appreciated thatthis process may be repeated down through three or more levels toprovide the customer with illustrations and order data forsub-sub-components and individual parts or supplies.

[0026] As stated above, upon selection of the component (sub-component,etc.), the web site server 110 and its associated software retrieves andsends the ordering data for a selected portion of said illustrationrepresenting at least one component of the at least one machine orotherwise corresponding to the selected subcomponent.

[0027] A sixth step 30, permits the customer to place an order; e.g.,the customer selects the component, sub-component, part or parts orsupplies based on the ordering data displayed, inputs quantityinformation, confirms the selection and information, and submits theorder.

[0028] In a seventh step 32, upon receipt of the submitted order, theweb site server 110 transmits a confirmation message that is received bythe customer. Preferably, prior to transmission of the confirmationmessage the server and its associated software electronically retrieveand verify on-hand inventory necessary to fill the order; generate allnecessary electronic and printed documentation; decrement supplyinformation according to the number of parts ordered; and electronicallyplace orders to replenish depleted inventory supplies.

[0029] In a first alternative embodiment, upon receipt of the requestedorder from the customer, the system includes a step 34 whereby the website server 110 electronically contacts a computer device associatedwith one or more vendors via a public or private network, such as theInternet. The web site server 110 and its associated software negotiateplacement of the order with the computer device of the vendor,whereafter the order is filled and shipped to the customer according toa predetermined plan.

[0030] In a second alternative embodiment, the system includes a furtherstep 36 whereby upon placement of the order by the customer, the website server 110 dynamically transfers all data pertinent to thesubmitted order to an automated accounting system. The accounting systemis capable of generating electronic or printed documentation 114 for thecustomer; e.g., a purchase order, a shipping bill, and an invoice.

[0031] In a third alternative embodiment, the customer utilizes anexpert information system 14 to receive information, including assembly,installation and repair instructions, from an expert 104 or engineer ofthe machine 100 who is stationed at a remote location.

[0032] Still referring to FIGS. 1 and 2, this third embodiment includesa step 38 whereby the machine 100 includes an imaging device 102 capableof transmitting real-time images of the machine 100. Preferably, theimaging device 102 is a digital video camera. However, a digitalphotographic camera or similar device may also be used. The imagingdevice 102 is preferably movably mounted on the machine 100 by means ofa cable or gantry, but may also be mount so that it is removable fromthe machine 100.

[0033] The imaging device 102 is preferably electronically connected toa user interface 106, such a laptop computer, which is capable oftransmitting an image of the machine 100 that is generated from theimaging device over a communications network to an expert 104 at aremote location. Preferably, the image is transmitted to the expert 104via a communications link 112 (e.g., the Internet). However, otherelectronic communication systems, such a radio, satellite, cable, etc.may also be used to carry and transmit the image to the expert.

[0034] The expert 104 is also preferably equipped with a user interface116 (e.g., a laptop computer) that permits real-time viewing of theimage being transmitted by the customer. The expert 104 can thus reviewthe image and, in further step 40, transmit expert information that isreceived by the customer regarding what action (if any) might beundertaken by the customer to assemble, install or repair the machine.The information received by the customer is preferably transmitted bythe expert 104 via the user interface 116. However, another means ofcommunication (e.g., telephone, videoconference, etc.) could also beused.

[0035] This system has particular advantages when the machine inquestion is a customized or otherwise unique machine that is not capableof being installed, constructed or repaired by a general servicecontractor.

[0036] Having illustrated and described the principles of the system andsystem of the present invention in various embodiments, it should beapparent to those skilled in the art that the embodiment can be modifiedin arrangement and detail without departing from such principles. Forexample, the physical manifestation of the computer media may be changedif preferred. Therefore, the illustrated embodiments should beconsidered only as example of the invention and not as a limitation onits scope.

We claim:
 1. A system for remote maintenance for a machine, the systemcomprising the steps of: providing a database having information for aplurality of machines; providing access to said database to display anillustration of at least one of said plurality of machines; and sendingordering data for a selected portion of said illustration representingat least one component of the at least one machine.
 2. The system ofclaim 1, further comprising the step of receiving an order for said atleast one component.
 3. The system of claim 2, further comprising thestep of transferring the order to an accounting system.
 4. The system ofclaim 3, further comprising the step of generating documentation for theorder.
 5. The system of claim 4, wherein said documentation is in anelectronic format.
 6. The system of claim 5, wherein said documentationis in a printed format.
 7. The system of claim 1, wherein said step ofsending confirmation of the transmitted order comprises sending aninventory verification.
 8. The system of claim 2, wherein said step ofreceiving an order for said at least one component compriseselectronically contacting a computer device associated with at least onevendor.
 9. The system of claim 1, wherein said ordering data comprisestechnical information.
 10. The system of claim 9, wherein said technicalinformation is selected from a group consisting of descriptions,dimensions, functions, tolerances and machine documentation.
 11. Thesystem of claim 1, wherein said ordering data comprises salesinformation.
 12. The system of claim 11, wherein said sales informationis selected from a group consisting of part numbers, descriptions, perunit and discount unit costs.
 13. The system of claim 1, furthercomprising the step of sending confirmation of the transmitted order.14. The system of claim 1, further comprising the step of sendingordering data for at least one sub-component of said component.
 15. Thesystem of claim 1, further comprising the step of receiving an image ofa machine transmitted by an imaging device.
 16. The system of claim 15,wherein said imaging device comprises a digital camera.
 17. The systemof claim 16, wherein said digital camera comprises a digital videocamera.
 18. The system of claim 15, further comprising the step oftransmitting expert information regarding the machine.
 19. The system ofclaim 18, wherein said expert information comprises assembly,installation, maintenance or repair information.